Installation

COMPONENTS FOR REMOVAL AND INSTALLATION





1. INSTALL INJECTORS AND DELIVERY PIPE.
- Install a new grommet to the injector.
- Apply a light coat of gasoline to a new 0-ring, and install it to the injector.





- While turning the injector clockwise and counterclockwise, push it to the delivery pipe. Install the 8 injectors.
- Position the injector connector outward.





- Place 8 new insulators and the 4 spacers in position on the intake manifold.





- Place the 8 injectors and 2 delivery pipes assembly in position on the intake manifold.
- Temporarily install the connector bracket and 4 nuts.





- Check that the injectors rotate smoothly.

HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of 0-rings. Replace the 0-rings.

- Position the injector connector upward.





- Tighten the 4 nuts holding the delivery pipes to the intake manifold.

Torque: 18 Nm (13 ft lb)





2. INSTALL FUEL RETURN PIPE.
- Install the return pipe with 2 new gaskets, union bolt and bolt.

Torque: 35 Nm (26 ft lb) for union bolt





3. TIGHTEN LOCK NUT ON FUEL PRESSURE REGULATOR.

Torque: 29 Nm (22 ft lb)

4. INSTALL ENGINE WIRE TO DELIVERY PIPES, REAR WATER BYPASS JOINT AND RH CYLINDER HEAD.
- Connect the 8 injector connectors.





- Connect the 2 engine wire connectors to the connector bracket on the LH delivery pipe.





- Install the engine wire to the RH cylinder head with the 2 bolts.
- Install the engine wire to the rear water bypass joint with the 2 bolts.
- Install the engine wire to the delivery pipes with the 4 bolts.





5. INSTALL ENGINE WIRE TO INTAKE MANIFOLD.
- Install the engine wire with the 2 bolts.





6. TEMPORARILY INSTALL EGR PIPE TO RH CYLINDER HEAD.
- Temporarily install the EGR pipe with the bolt.
7. CONNECT FUEL RETURN HOSE TO FUEL RETURN PIPE.





8. CONNECT FUEL INLET HOSE TO LH DELIVERY PIPE.
- Using SST 09612-24014, connect the inlet hose with 2 new gaskets and pulsation damper.

Torque:
39 Nm (29 ft lb) not using SST
33 Nm (24 ft lb) for SST

HINT: Use a torque wrench with a fulcrum length of
30cm (11.81 in).





9. INSTALL AIR INTAKE CHAMBER ASSEMBLY.
- Place 4 new air intake chamber gaskets on the intake manifold.
- Connect the EGR gas temperature sensor connector.
- Place the air intake chamber assembly on the intake manifold.





- Temporarily install a new gasket and the EGR pipe to air intake chamber with the 2 bolts.





- Install the connector bracket to the DLC1.
- Install the air intake chamber and following parts with the 4 bolts and 8 nuts:
- Vacuum Switching Valve (VSV) for fuel pressure control
- VSV for EVAP
- Transmission throttle cable bracket
- DLC1

Torque: 18 Nm (13 ft lb)

HINT: Use bolts 40 mm (1.57 in) of length.





- Tighten the bolts holding the EGR pipe to the air intake chamber.

Torque: 18 Nm (13 ft lb)

( - Tighten the bolt holding the EGR pipe to the RH cylinder head.

Torque: 18 Nm (13 ft lb)





- Install the accelerator bracket with the bolt and stud bolt.





10. CONNECT HOSES:
- Connect the following hoses:
- Water bypass hose to EGR valve
- Vacuum hose to air intake chamber
- PCV hose to LH cylinder head cover





- Water bypass hose to Idle Air Control (IAC) valve
- Air hose to air intake chamber
- Vacuum sensing hose to fuel pressure regulator
11. CONNECT CONNECTORS:
- Connect the following connectors:
- IAC valve connector
- EGR valve connector
- VSV connector for fuel pressure control
- VSV connector for EVAP system
- EGR gas temperature sensor connector





12. INSTALL THROTTLE BODY.
- Connect the following hoses to the throttle body:
- PCV hose
- Water bypass hose





- Install a new gasket and throttle body with the 2 bolts and 2 nuts.

Torque: 18 Nm (13 ft lb)

HINT: Use bolts 40 mm (1.57 in) in length.

- Install the water bypass pipe (from rear water bypass joint) to the clamp on the engine wire cover.





- Connect the following hoses:
- Water bypass hose to IAC valve
- Vacuum hose to throttle body





- Heater water hose to heater water valve





- Connect the following connectors:
- Throttle position sensor connector
- w/TRAC: Sub-throttle position sensor connector
- w/TRAC: Sub-throttle actuator connector





13. INSTALL LOWER HIGH-TENSION CORD COVER.
- Connect the end portions of the high -tension cord to the cord clamps.
- Install the high-tension cord cover with the bolt.





- Install the clamps on the high-tension cords to the high-tension cord cover.
- Connect the high-tension cord to the RH ignition coil.





14. INSTALL RH NO.3 TIMING BELT COVER.
- Install the 3 gaskets to the timing belt cover.
- Fit the portion A of the timing belt cover, matching it with the lower high-tension cord cover.
- Install the timing belt cover with the 4 bolts.





- Connect the 2 air control valve hoses.





15. INSTALL LH NO.3 TIMING BELT COVER.
- Install the 3 gaskets to the timing belt cover.
- Install the cord grommet to the high-tension cord (from the LH ignition coil).
- Install the cord grommet to the timing belt cover.
- Fit the portion A of the timing belt cover, matching it with the
lower high-tension cord cover.
- Install the timing belt cover with the 4 bolts.





16. INSTALL RH ENGINE WIRE COVER.
- Fit the portions A and B of the engine wire cover, matching them with the lower high-tension cord cover and No.3 timing belt cover.
- Install the engine wire cover with the bolt.





17. INSTALL LH ENGINE WIRE COVER.
- Connect the portions A and B of the engine wire cover to the wire brackets.
- Set the VSV (for the fuel pressure) wire in original position.
- Fit the portions C and D of the engine wire cover, matching them with the lower high-tension cord cover and No.3 timing belt cover.
- Install the engine wire cover with the 2 bolts.





18. INSTALL UPPER HIGH-TENSION CORD COVER.
- Fit portion A of the upper high-tension cord cover matching the top of the lower high-tension cord cover.





- Push the front side of the upper high-tension cord cover. and fit the front side claw groove of the upper high-tension cord cover to the claw of the lower high -tension cord cover.
- Install the upper high-tension cord cover with the 2 bolts.





19. INSTALL INTAKE AIR CONNECTOR.
- Connect the end portions of the intake air connector to the throttle body and air cleaner hose.
- Tighten the 2 hose clamps.
- Install the bolt holding the intake air connector to the cylinder head cover.





- Connect the following hoses:
- Air hose to IAC valve
- Air hose (from air control valve on PS pump) to intake air connector





20. CONNECT CONTROL CABLES TO THROTTLE BODY.
- Connect the following hoses:
- Accelerator cable
- Transmission throttle control cable
- Cruise control actuator cable





21. INSTALL THROTTLE BODY COVER.
- Install the throttle body cover and hose clamp with the cap nut and 2 bolts.
- Install the EVAP hose to the hose clamp.
22. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY.
23. FILL ENGINE WITH COOLANT.
24. CHECK FOR FUEL LEAKS.